3 Owner s Manual. Serial Number Here. Date of Purchase New Hope Road, Raleigh, NC Fusion

Transcription

1 Revision 2 Feb Owner s Manual Serial Number Here Date of Purchase New Hope Road, Raleigh, NC Fusion 3 Owner s Manual

2 Instructions Congratulations on the purchase of your new Fusion 3. This gym will provide you with a lifetime of enjoyment to meet your strength training needs. Batca Fitness Systems strives to build the best quality multi-station gyms and to package these gyms in such a way to avoid any damage during shipping. In order to get started with your assembly you should first familiarize yourself with this manual. It is recommended that you read through each step thoroughly before you begin. Begin by opening your boxes and separating all of your parts. Verify that all parts are accounted for and have no damage. When all parts are accounted for, you may begin your assembly. Some items may have been pre-assembled for your convenience. Please note that hardware quantities shown reflect total quantities for your gym and may not reflect actual quantities in each bag. Assemble your gym on a solid level surface. This will ensure the best possible performance, function, and safety for the gym and your workout. Assemble your gym according to the step by step instructions found in this manual. Failure to do so will void your warranty and may result in personal injury. After assembly, you should check each station to ensure correct operation. If a problem arises, recheck your assembly with these instructions to verify correct assembly. If you are unable to correct a problem or have questions with your assembly please contact your authorized Batca dealer. Warning Batca Fitness Systems has built this gym to give you a safe, effective and enjoyable workout. However, there is a risk assumed by individuals who use this type of equipment. It is very important that all warnings and instructions are read and followed before beginning any exercise program. It is also very important to read and follow the preventative maintenance schedule described in this manual. If any of the warning labels or stickers are worn, faded, torn, scratched or missing they should be replaced immediately. WARNING: There is a risk assumed by individuals who use this type of equipment. To minimize risk always follow these rules. 1) It is essential that you consult with your physician before beginning any exercise program. 2) Inspect equipment before each use for loose, worn, or frayed parts (including cables, nuts and bolts). Replace parts at first signs of wear (use only genuine BATCA replacement parts). Use of equipment that is damaged, worn, frayed or not completely assembled on a solid, level surface may result in injury. 3) Make sure all adjustment pins are fully engaged before using equipment. 4) Keep all parts of the body and clothing outside the path of any moving parts of the gym. Be alert to the possibility of injury. Do not be careless. 5) Minors and children should not be allowed to play on or around this gym. 6) If you have any questions on proper use or maintenance of this gym, do not hesitate to call your local BATCA FITNESS SYSTEMS distributor or BATCA FITNESS SYSTEMS at (919) Table of Contents Page Instructions 2 Parts Listing 3-5 Hardware Comparison 6-9 Cable Comparison 10 Main Frame Assembly Cable Routing Upholstery Leg Press Option Page Leg Press Cable Routing 32 Leg Press Attachment 34 Weight Stack Decals and Serial Number 35 Cable Tension and Adjustments Final Assembly and Troubleshooting 38 Maintenance 39 Warranty 40 Floor plan Layout Batca Fitness Systems 2 Fusion 3 Owner's Manual

3 ITEM NO. PART NO. DESCRIPTION QTY 1 BFM Rear Base 1 2 BFM Right Vertical Support 1 3 BFM Left Vertical Support 1 4 BFM Middle Base 1 5 BFM Middle Pole Assembly 1 6 BFM Guide Rod Holder 1 7 BFM /4" Spacer 6 9 BFM Rubber Donut 2 10 BFM Weight Plate BFM Guide Rod 2 13 BFM Right Arm Assembly 1 14 BFM Left Arm Assembly 1 15 BFM Functional Arm Mount 1 16 BFM User Right Functional Arm 1 17 BFM User Left Functional Arm 1 18 BFL Middle Pole Connector Plate 2 19 BFL Pulley Holder Connector Plate 1 20 BFM " Telespar 1 21 BFM Seat Frame Assembly 1 24 BFM " Chrome Adjustment 1 25 BFM Knee Alignment Roller 1 30 BFM Back Chrome Adjustment 1 33 BFM Leg Extension/ Curl Frame 1 35 BFM Spacer 1 36 BFM-10582rev1 Functional Arm Swivel Pulley 2 37 BFM Top Swivel Pulley Holder 2 38 BFM Weight Stack Shroud 2 39 BFM Leg Extension Shaft 1 40 BFM Leg Extension Cam Assembly 1 41 BFM /4" OD x.120 Wall x.225" Spacer 1 42 BFM Leg Extension Arm Assembly 1 44 BFL Hold Down Adjustment Plate 1 45 BFL Plate 1 46 BFM Knee Hold Down Assembly 1 47 BFM Axle 1 48 BFM Knee Hold Down Handle 1 50 BFL Pulley Plate 1 53 BFM Anti-Deflection Plate 1 54 BFM " x 13 3/16" Arm Shaft 1 77 BFM /2" Pulley Cover BFM Left Arm Adjustment Handle 1 80 BFM Right Arm Adjustment Handle 1 87 BFM " OD x 25/64" ID Spacer 1 91 BFM Press Arm 2 93 BFM-10609rev1 Pulley Holder 2 94 BFM Criss-Cross Free Floater 1 96 BFM-10610rev1 Lower Pulley Holder BFM Cable Tie Out Plate BFM Top Plate BFM Selector Shaft BFM /16 Axle BFM Axle BFM Weight Stack Pull Pin BFM Front Pivot BFM Spacer 1 Frame Components ITEM NO. PART NO. DESCRIPTION QTY 191 BFM Right Press Arm Assembly BFM-10737rev1 Right Swing Arm Assembly BFM-10733rev1 Left Swing Arm Assembly BFM Left Press Arm Assembly BFM Weight Stack Shroud w/logo 1 Accessories ITEM NO. PART NO. DESCRIPTION QTY 156 BFC Strap Handle BFM Press Arm Lock (Optional) 1 Upholstery ITEM NO. PART NO. DESCRIPTION QTY 31 BFU Large Bottom Pad 1 11 BFU Head Pad 1 32 BFU Back Pad With Lum BFU Large Roller 1 28 BFU " Roller Fusion 3 Owner s Manual

4 Hardware ITEM NO. PART NUMBER DESCRIPTION QTY 8 BFH /2" Pulley BFH /2" Flanged Bushing 4 23 BFH /8" Flanged Bushing 2 26 BFH Rubber Bumper 2 27 BFH " Plastic Washer 4 29 BFH Plastic Collar 6 34 BFH " Flanged Bushing BFH " Round Plastic Cap 5 51 BFH Threaded Bearing 2 55 BFH " Snap Ring 7 56 BFH /8" Flat Washer (Black) BFP SHCS 3/8"-16 X 2 1/4" BFH /8"-16 Nylock (Black) BFH SHCS 3/8"-16 X 5 1/4" 8 60 BFH /8" Lock Washer (Black) BFP SHCS 3/8"-16 X 1 1/4" 4 62 BFP SHCS 3/8"-16 X 2 3/4" 8 63 BFP SHCS 3/8"-16 X 3" 5 64 BFH /2" Flat Washer (Black) 4 65 BFP SHCS 1/2-13 X 3 1/ BFP SHCS 1/2-13 X 4 1/ BFP SHCS 1/2-13 X BFH /2"-13 Nylock (Black) 3 70 BFP SHCS 3/8"-16 X 2" BFP SHCS 3/8"-16 X 4 3/4" 6 73 BFP SHCS 3/8" /4" 2 74 BFP SHCS 3/8"-16 X 5 1/2" 2 75 BFH /8" Pulley Spacer 2 76 BFP SHCS 3/8"-16 X 2 1/2" 3 92 BFH /2 Jam Nut 6 95 BFH /2" Pulley 4 98 BFH Beveled Leveler 2 99 BFH /8"-16 Jam Nut (Zinc) BFH Large Logo/Chrome & Red BFH Weight Stack Decals 2 Cables ITEM NO. PART NUMBER DESCRIPTION QTY 113 BFH /8" Shoulder Bolt BFH /16"-18 Nylock (Black) BFH FHSCS 3/8"-16 X 1" BFP SHCS 3/8-16 X 3/ BFP SHCS 3/8-16 X 5" BFH FHSCS 5/16"-18 X 1" BFH Snap Hook BFH " Square Plastic Cap BFH " x 3" Plastic Cap BFH /2" Square Plastic Cap BFH Cable Strap BFH Pin BFH Snap Ring BFH /2" Bronze Bushing BFH /32" Bushing BFH " Flanged Bushing x 1/2"L BFH Plastic Sleeve BFH " ID Bearing BFH " Interior Snap Ring BFH Pull Pin Threaded Cap BFH " Plastic Sleeve BFH Molded Grip 1" ID BFH " Round Plastic Cap BFH /4" x 4" Rectangular Cap BFH " Rubber Grips BFH Mounting Bracket BFH /2" Curved Pulley Spacer BFH /8 Curved Washer (Black) BFH Large Flat Leveler BFH Wavy Washer BFH FHSCS 3/8-16 X 3/ BFP BHSCS 3/8-16 X 1/ BFH BHSCS 3/8-16 X 3/ BFH Upholstery Cap BFH BHSCS 3/8 x BFM /2 Aluminum Cap BFH Shaft Collar BFM Red Pivot Point Cap 1 ITEM PART NUMBER DESCRIPTION QTY 101 CAB Fusion Lat Pull to Functional Arm CAB Fusion Weight Stack to Cable Tie Out CAB Fusion Floating Pulley Cable CAB Fusion Leg Extension Cable CAB Fusion Tie Out Cable 1 Batca Fitness Systems 4 Fusion 3 Owner's Manual

5 Leg Press Components ITEM NO. PART NUMBER DESCRIPTION Qty 172 BFP Foot Plate BFL Bench Frame Plate BFM Chrome Pad Adjustment BFM Leg Press Connector Assembly BFP Leg Press Pivot Arm BFM Chrome Adjustment BFM " Telespar BFP Four Bar Spacer 2 ITEM NO. PART NUMBER DESCRIPTION Qty 166 BFM Back Seat Frame BFM Bottom Seat Frame BFM-10605rev1 Leg Press Frame BFP Four Bar BFM /32" Axle BFM /32" Axle BFM Front Pivot 1 Leg Press Hardware ITEM NO. PART NUMBER DESCRIPTION Qty 61 BFP SHCS 3/8"-16 X 1 1/4" P BFP SHCS 3/8"-16 X 2" P BFP SHCS 3/8"-16 X 2 1/2" P BFP SHCS 3/8"-16 X 3" P BFP SHCS 3/8"-16 X 3 1/4" P BFP SHCS 3/8"-16 X 3 1/2" P BFP SHCS 3/8"-16 X 4 1/4" P BFP SHCS 3/8"-16 X 4 1/2" P BFH /8" Flat Washer (Black) BFH /8" Lock Washer (Black) 4 99 BFH /8"-16 Jam Nut (Zinc) 3 58 BFH /8"-16 Nylock (Black) 22 8 BFH /2" Pulley 5 ITEM NO. PART NUMBER DESCRIPTION Qty 113 BFH /8" Shoulder Bolt 1 64 BFH /2" Flat Washer (Black) 2 98 BFH Beveled Leveler BFH /16"-18 Nylock (Black) 1 59 BFP SHCS 3/8"-16 X 5 1/4" P BFP SHCS 3/8" /4" P BFH /8" Pulley Spacer 5 92 BFH /2 Jam Nut BFH Large Flat Leveler BFP Aluminum Cap BFH BHSCS 3/8 x 1 4 Cables Tools Required ITEM NO. PART NUMBER DESCRIPTION Qty 102 CAB Fusion Leg Press Cable 1 Upholstery ITEM NO. PART NUMBER DESCRIPTION Qty 173 BFU Large Bottom Pad BFU Back Pad With Lumbar 1 1/2 Wrench 9/16 Wrench 9/16 Ratchet 3/4 Wrench 3/4 Ratchet Allen Wrench Set Tape Measure Snap Ring Pliers 5 Fusion 3 Owner s Manual

6 Bolt Length Note: Bolt length is measured from the underside of the head of the bolt. Batca Fitness Systems 6 Fusion 3 Owner's Manual

7 Beveled Leveler BFH Large Flat Leveler BFH Plastic Washer Upholstery Cap 3 1/2 Pulley BFH Threaded Bearing BFH Pin BFH /2 Pulley BFH Cable Strap BFH Strap Handle BFC Snap Hook BFH Fusion 3 Owner s Manual

8 Batca Fitness Systems 8 Fusion 3 Owner's Manual

9 Long Pop Pin BFM Magnetic Weight Stack Pin BFM Short Pop Pin BFM Pop Pin Cap BFM Rubber Donut BFM Plastic Cap Part # Size BFH X 2 BFH X 3 BFH /2 X 2 BFH /4 X 1 3/4 BFH /2 X 1 1/2 3/8 Curved Washer BFM /8 Flat Washer BFM /2 Flat Washer BFM /8 Lock Washer BFM Mounting Brackets BFH /4 x 4 Rectangular Cap BFH Rubber Grips (Yellow) BFH Fusion 3 Owner s Manual

10 Cable Comparison Chart 187 1/2 85 1/4 CAB CAB /8 90 1/2 CAB CAB /8 22 5/8 CAB CAB Cables ITEM NO. PART NUMBER DESCRIPTION QTY 101 CAB Fusion Lat Pull to Functional Arm CAB Fusion Weight Stack to Cable Tie Out CAB Fusion Leg Press Cable CAB Fusion Floating Pulley Cable CAB Fusion Leg Extension Cable CAB Fusion Tie Out Cable 1 Batca Fitness Systems 10 Fusion 3 Owner's Manual

11 PLEASE FOLLOW ALL DIRECTIONS VERY CAREFULLY FOR PROPER INSTALLATION. Step 1: Note: For a more consistent appearance, position all bolts in the direction shown in each figure. All Flat Washers and Nylocks are 3/8 unless otherwise noted. Do Not Tighten Hardware Until Step 3 Item # Part # Description Qty 1 BFM Rear Base 1 2 BFM Left Vertical Support 1 3 BFM Right Vertical Support 1 4 BFM Middle Base 1 37 BFM Top Swivel Pulley 2 Figure 1 55 BFH Snap Ring 4 56 BFH /8" Flat Washer (Black) 8 57 BFH /8"-16 Nylock (Black) 4 58 BFP SHCS 3/8"-16 X 5 1/4" P BFP SHCS 3/8-16 X 5" P BFH Wavy Washer Fusion 3 Owner s Manual

12 Step 2: Do Not Tighten Hardware Until Step 3 Figure 2 All Flat Washers and Nylocks are 3/8 unless otherwise noted. Item # Part # Description Qty 5 BFM Middle Pole Assembly 1 18 BFL Middle Pole Connector Plate 2 56 BFH /8" Flat Washer (Black) BFH /8"-16 Nylock (Black) 4 59 BFP SHCS 3/8"-16 X 5 1/4" P BFH /8 Lock Washer (Black) 2 76 BFP SHCS 3/8"-16 X 2 1/2" P BFH Beveled Leveler 2 99 BFH /8"-16 Jam Nut (Zinc) BFH Large Flat Leveler 2 Batca Fitness Systems 12 Fusion 3 Owner's Manual

13 Step 3: Tighten All Hardware From Steps 1, 2, and 3 Figure 3 Item # Part # Description Qty 200 BFM Press Arm Lock (Optional) BFM Right Press Arm Assembly BFM-10737rev1 Right Swing Arm Assembly BFM-10733rev1 Left Swing Arm Assembly BFM Left Press Arm Assembly 1 35 BFM Spacer 1 54 BFM " Arm Shaft 1 All Flat Washers and Nylocks are 3/8 unless otherwise noted. 182 BFH Wavy Washer BFH BHSCS 3/8 x BFM /2 Aluminum Cap BFH Shaft Collar 2 Fusion 3 Owner s Manual

14 Step 4: Figure 4 All Flat Washers and Nylocks are 3/8 unless otherwise noted. Item # Part # Description Qty 6 BFM Guide Rod Holder 1 9 BFM Rubber Donut 2 10 BFM Weight Plate BFM Guide Rod 2 38 BFM Weight Stack Shroud 1 56 BFH /8" Flat Washer (Black) BFH /8"-16 Nylock (Black) 2 60 BFH /8" Lock Washer (Black) BFM Top Plate 1 Item # Part # Description Qty 195 BFM Weight Stack Shroud w/logo BFM Selector Shaft BFH Weight Stack Decals BFP SHCS 3/8-16 X 3/ BFP SHCS 3/8"-16 X 5" P BFM Weight Stack Pull Pin BFH FHSCS 3/8"-16 X 3/4" BFP BHSCS 3/8"-16 X 1/2" 4 Batca Fitness Systems 14 Fusion 3 Owner's Manual

15 Step 5: All Flat Washers and Nylocks are 3/8 unless otherwise noted. Figure 5 Item # Part # Description Qty 15 BFM Functional Arm Mount 1 16 BFM User Right Functional Arm 1 17 BFM User Left Functional Arm 1 36 BFM-10582rev1 Functional Arm Swivel Pulley 2 56 BFH /8" Flat Washer (Black) 4 58 BFH /8"-16 Nylock (Black) 2 61 BFP SHCS 3/8" /4" P Fusion 3 Owner s Manual

16 Step 6: 8 Anti-Deflection Plate Figure 6 All Flat Washers and Nylocks are 3/8 unless otherwise noted. Item # Part # Description Qty 20 BFM " Telespar 1 24 BFM " Chrome Adjustment 1 33 BFM Leg Extension/ Curl Frame 1 53 BFM Anti-Deflection Plate 1 56 BFH /8" Flat Washer (Black) 6 58 BFH /8"-16 Nylock (Black) 4 64 BFH /2" Flat Washer Black 2 66 BFP SHCS 1/2-13 X 4 1/4 P BFH /2"-13 Nylock (Black) 1 74 BFP SHCS 3/8"-16 X 5 1/2" BFH FHSCS 3/8"-16 X 1" BFM Axle 1 Batca Fitness Systems 16 Fusion 3 Owner's Manual

17 Step 7: Figure 7 All Flat Washers and Nylocks are 3/8 unless otherwise noted. Item # Part # Description Qty 21 BFM Seat Frame Assembly 1 30 BFM Back Chrome Adjustment 1 64 BFH /2" Flat Washer (Black) 4 65 BFP SHCS 1/2-13 X 3 1/ BFP SHCS 1/2-13 X 3 P BFH /2"-13 Nylock (Black) Fusion 3 Owner s Manual

18 Step 8: SHCS Figure 8 All Flat Washers and Nylocks are 3/8 unless otherwise noted. Item # Part # Description Qty 25 BFM Knee Alignment Roller 1 39 BFM Leg Extension Shaft 1 40 BFM Leg Extension Cam Assembly 1 55 BFH " Snap Ring 1 58 BFH /8"-16 Nylock (Black) 1 70 BFP SHCS 3/8"-16 X 2" BFH FHSCS 5/16"-18 X 1" BFM /16 Axle BFH Wavy Washer 2 Batca Fitness Systems 18 Fusion 3 Owner's Manual

19 Step 9: Figure 9 All Flat Washers and Nylocks are 3/8 unless otherwise noted. Item # Part # Description Qty 42 BFM Leg Extension Arm Assembly 1 44 BFL Hold Down Adjustment Plate 1 45 BFL Plate 1 46 BFM Knee Hold Down Assembly 1 47 BFM Axle 1 55 BFH " Snap Ring 2 56 BFH /8" Flat Washer (Black) 6 58 BFH /8"-16 Nylock (Black) 3 63 BFP SHCS 3/8"-16 X 3" P BFH Wavy Washer BFH BHSCS 3/8 x BFM Red Pivot Point Cap Fusion 3 Owner s Manual

20 Cable Routing Step 10: Note: Each Cable with a threaded bolt on either end must be threaded at least 1 / 2 i n t o i t s attachment. 1 3/8 Figure /8 Item # Part # Description Qty 8 BFH /2" Pulley 2 CAB BFH /8" Flat Washer (Black) 6 57 BFP SHCS 3/8"-16 X 2 1/4" P BFH /8"-16 Nylock (Black) 3 92 BFH /2 Jam Nut 1 94 BFM Criss-Cross Free Floater 1 All Flat Washers and Nylocks 95 BFH /2" Pulley 1 are 3/8 unless otherwise 109 CAB Fusion Weight Stack to Cable Tie Out 1 noted. 113 BFH /8" Shoulder Bolt BFH /16"-18 Nylock (Zinc) 1 Batca Fitness Systems 20 Fusion 3 Owner's Manual

21 Step 11: Note: Each Cable with a threaded bolt on either end must be threaded at least 1/2 into its attachment. 85 1/4 CAB All Flat Washers and Nylocks are 3/8 unless otherwise noted. Figure 11 Item # Part # Description Qty 56 BFH /8" Flat Washer (Black) 6 57 BFP SHCS 3/8"-16 X 2 1/4" P BFH /8"-16 Nylock (Black) 3 92 BFH /2 Jam Nut 2 93 BFM-10609rev1 Pulley Holder 2 95 BFH /2" Pulley 3 96 BFM-10610rev1 Lower Pulley Holder CAB Fusion Floating Pulley Cable Fusion 3 Owner s Manual

22 Step 12: Note: If Leg Press Option is purchased skip this step and continue to Step 13 on Page 23. Note: Each Cable with a threaded bolt on either end must be threaded at least 1/2 into its attachment. 22 5/8 CAB Item # Part # Description Qty Figure BFL Pulley Holder Connector Plate 1 56 BFH /8" Flat Washer (Black) 4 58 BFH /8"-16 Nylock (Black) 2 59 BFP SHCS 3/8"-16 X 5 1/4" P5 2 All Flat Washers and Nylocks are 92 BFH /2 Jam Nut 2 3/8 unless otherwise noted. 105 BFM Cable Tie Out Plate CAB Fusion Tie Out Cable 1 Batca Fitness Systems 22 Fusion 3 Owner's Manual

23 Step 13: Note: If Leg Press Option is purchased later, remove CAB and Cable Tie-Out Plate from Step 12 on Page /8 Figure /2 Note: Each Cable with a threaded bolt on either end must be threaded at least 1/2 into its attachment. CAB All Flat Washers and Nylocks are 3/8 unless otherwise noted. Item # Part # Description Qty 8 BFH /2" Pulley 5 60 BFH /8 Lock Washer (Black) 1 50 BFL Pulley Plate 1 56 BFH /8" Flat Washer (Black) 7 57 BFP SHCS 3/8"-16 X 2 1/4" P BFH /8"-16 Nylock (Black) 4 70 BFP SHCS 3/8-16 X 2 P BFP SHCS 3/8" /4" P5 1 Item Part # Description Qty 75 BFH /8" Pulley Spacer 2 76 BFP SHCS 3/8"-16 X 2 1/2" 1 77 BFM /2" Pulley Cover 1 92 BFH /2 Jam Nut CAB Fusion Leg Extension Cable BFH /8" Shoulder Bolt BFH /16"-18 Nylock (Zinc) BFM Spacer Fusion 3 Owner s Manual

24 Step 14: 3/8 x 2 Note: Reverse side of Fusion to better see nuts, bolts, pulley spacers, and pulley s Note: Cable used is CAB-13020, Fusion Lat Pull to Functional Arm User Right 188 1/2 CAB All Flat Washers and Nylocks are 3/8 unless otherwise noted. Figure 14 Item # Part # Description Qty Item # Part # Description Qty 7 BFM /4 Spacer 3 70 BFP SHCS 3/8"-16 X 2" P5 5 8 BFH /2" Pulley BFP SHCS 3/8"-16 X 4 3/4" P BFH /8" Flat Washer (Black) BFM /2" Pulley Cover 4 57 BFP SHCS 3/8"-16 X 2 1/4" CAB Fusion Lat Pull to Functional Arm 1 58 BFH /8"-16 Nylock (Black) BFH /2" Curved Pulley Spacer 4 62 BFP SHCS 3/8-16 X 2 3/ BFH /8" Curved Washer (Black) BFH /8 Shoulder Bolt 1 Batca Fitness Systems 114 BFH /16"-18 Nylock (Zinc) 1 24 Fusion 3 Owner's Manual

25 Step 14: Continued 3/8 x 4 3/4 (Qty=3) Start Here 3/8 x 2 1/4 Assembly Tip: It is important in order to avoid any cable twisting that the cable is routed around each pulley individually and pulled all the way through before routing around the next pulley in the cable routing sequence. If this is not done properly damage and twisting to the cable can occur. Also, remove cable end before routing. 3/8 x 2 3/4 (Qty=2) 3/8 Shoulder Bolt 3/8 Curved Washer A B C 1/2 Curved Pulley Spacer (Qty=4) A B C 3/8 x 2 3 1/2 Pulley Cover D 3/8 x 2 1/4 D 3/8 x 2 1/4 (Qty=3) 3/8 x 2 (Qty=2) 3/8 x 2 1/4 Swivel Pulley Counterweight 3/8 x 2 Step 15: Repeat for alternate side of Fusion. Use same Bill of Materials from Step 14 for Step 15. Use CAB-13021, Fusion Lat Pull to Functional Arm. All Flat Washers and Nylocks are 3/8 unless otherwise noted. 1 3/8 Shoulder Bolt 25 Fusion 3 Owner s Manual

26 Step 16: (Qty=4) Figure 16 All Flat Washers and Nylocks are 3/8 unless otherwise noted. Item # Part # Description Qty 27 BFH " Plastic Washer 4 28 BFU " Roller 6 43 BFU Large Roller 1 48 BFM Knee Hold Down Handle 1 58 BFH /8"-16 Nylock (Black) 1 73 BFP SHCS 3/8"-16 X 1 3/4" P BFH /8 Curved Washer BFH BHSCS 3/8-16 X 3/4 P BFH Upholstery Cap 6 Batca Fitness Systems 26 Fusion 3 Owner's Manual

27 Step 17: Figure 17 All Flat Washers and Nylocks are 3/8 unless otherwise noted. Item # Part # Description Qty 11 BFU Head Pad 1 31 BFU Large Bottom Pad 1 32 BFU Back Pad With Lumbar 1 56 BFH /8" Flat Washer (Black) 6 60 BFH /8" Lock Washer (Black) 6 61 BFP SHCS 3/8-16 x 1 1/4 P BFP SHCS 3/8"-16 X 2 3/4" P BFP SHCS 3/8"-16 X 3" P BFC Strap Handle Fusion 3 Owner s Manual

28 Leg Press Option Step 18: Note: This step may be pre-assembled Figure 18 All Flat Washers and Nylocks are 3/8 unless otherwise noted. Item # Part # Description Qty 157 BFM-10605rev1 Leg Press Frame BFM Leg Press Connector 1 56 BFH /8" Flat Washer (Black) 4 59 BFP SHCS 3/8"-16 X 5 1/4" P BFH /8"-16 Nylock (Black) BFP Four Bar BFP Four Bar Spacer BFP Leg Press Pivot Arm 1 Batca Fitness Systems 28 Fusion 3 Owner's Manual

29 Step 19: Note: This step may be pre-assembled Figure 19 All Flat Washers and Nylocks are 3/8 unless otherwise noted. Item # Part # Description Qty 160 BFM /32" Axle BFM /32" Axle BFM " Telespar BFL Bench Frame Plate BFM Chrome Adjustment BFM Front Pivot 1 56 BFH /8" Flat Washer (Black) 6 82 BFP SHCS 3/8"-16 X 3 1/2" 1 69 BFP SHCS 3/8"-16 X 3 1/4" 1 83 BFP SHCS 3/8"-16 X 4 1/4" 1 58 BFH /8"-16 Nylock (Black) Fusion 3 Owner s Manual

30 Step Note: This step may be pre-assembled Figure 20 All Flat Washers and Nylocks are 3/8 unless otherwise noted. Part # Description Qty 159 BFM /32" Axle BFM Bottom Seat Frame BFM Chrome Pad Adjustment BFM Back Seat Frame 1 56 BFH /8" Flat Washer (Black) 8 82 BFP SHCS 3/8"-16 X 3 1/2" P BFP SHCS 3/8"-16 X 4 1/2" P BFP SHCS 3/8"-16 X 3 1/4" P BFH /8"-16 Jam Nut (Zinc) 1 98 BFH Beveled Leveler 1 58 BFH /8"-16 Nylock (Black) 4 Batca Fitness Systems 30 Fusion 3 Owner's Manual

31 Step 21: Figure 21 All Flat Washers and Nylocks are 3/8 unless otherwise noted. Item # Part # Description Qty 56 BFH /8" Flat Washer (Black) BFP Foot Plate Assembly BFP Aluminum Cap BFH BHSCS 3/8 x Fusion 3 Owner s Manual

32 Step 22: 1 3/8 Figure /8 CAB All Flat Washers and Nylocks are 3/8 unless otherwise noted. Item # Part # Description Qty 56 BFH /8" Flat Washer (Black) 4 60 BFH /8 Lock Washer (Black) 1 75 BFH /8" Pulley Spacer 5 76 BFP SHCS 3/8"-16 X 2 1/2" 2 73 BFP SHCS 3/8" /4" P BFP SHCS 3/8"-16 X 2" P BFH /8"-16 Nylock (Black) 4 8 BFH /2" Pulley CAB Fusion Leg Press Cable BFH /8" Shoulder Bolt BFH /16"-18 Nylock (Black) 1 Batca Fitness Systems 32 Fusion 3 Owner's Manual

33 Step 23: Figure 23 All Flat Washers and Nylocks are 3/8 unless otherwise noted. Item # Part # Description Qty 173 BFU Large Bottom Pad BFU Back Pad With Lumbar 1 56 BFH /8" Flat Washer (Black) 4 60 BFH /8" Lock Washer (Black) 4 61 BFP SHCS 3/8"-16 X 1 1/4" 2 63 BFP SHCS 3/8"-16 X 3" P Fusion 3 Owner s Manual

34 Step 24: Note: Each Cable with a threaded bolt on either end must be threaded at least 1/2 into its attachment. Figure 24 All Flat Washers and Nylocks are 3/8 unless otherwise noted. Item # Part # Description Qty 56 BFH /8" Flat Washer (Black) 4 58 BFH /8"-16 Nylock (Black) 2 59 BFP SHCS 3/8"-16 X 5 1/4" 2 92 BFH /2 Jam Nut 1 99 BFH /8-16 Jam Nut 1 Batca Fitness Systems 34 Fusion 3 Owner's Manual

35 Step 25: Weight Stack Decals: 200lb Stack (Standard) Guide Rod Lubrication: Clean guide rods with a lint-free cloth and apply a thin layer of silicon lubricant (Part # BFH-50262) to each guide rod. This will ensure a glass smooth performance from your weight stack. Serial Number: Record your serial number on the front of this manual and keep for your records. The serial number can be found on the back of the cage as seen in the figure Fusion 3 Owner s Manual

36 Cable Adjustments Adjust cables to proper tension from any of the locations shown below. How to Begin: In order to get the proper tension in your cables, it is recommended that you follow the sequence 1-8 as shown on pages 36 and 37. The numbers for this sequence can be found in the upper left corner of each of the detailed views. Each detailed view below will refer you to the original Figure for more detailed information. Follow the detailed information found in each referenced figure. Note: Adjustment 7 Figure 12 is only used on units that did not receive the Leg Press Option. Note: If the top plate raises off of the second plate in the weight stack, then the cable tension is too tight. You will need to take some of the tension out to lower the Top plate flush with the second plate. 3 5 Refer to Figure 14 Refer to Figure 11 7 Refer to Figure 12 and 24 8 Refer to Figure 24 Note: All cables with threaded adjustable ends must have at least 1/2 of the threads threaded into its counterpart. It is very important that the 1/2 Jam Nut (92) be wrench tightened to the counterpart to ensure that the threaded adjustable end of the cable does not back out of its counterpart. Batca Fitness Systems 36 Fusion 3 Owner's Manual

37 2 1 4 Refer to Figure 14 Refer to Figure 10 Refer to Figure 11 Note: All levelers (Beveled (98) or Large Flat (181)) should have at least 1/2 of the threads threaded in to its counterpart. It is very important that the 3/8 Jam Nut (99) be wrench tightened to the counterpart to ensure that the leveler does not back out of the counterpart. 6 Refer to Figure Fusion 3 Owner s Manual

38 Final Assembly and Troubleshooting IMPORTANT - Check These Components Before Using Gym: Position the cable guard tab on the Pulley Cover so that the tab prevents the cable from coming out of it s track on the 3 1/2 Pulley. An example of this positioning can be seen in the figure to the right. The cable guard tab should be positioned so that it is in the middle of the cable wrap on the 3 1/2 Pulley, between points A and B. This will allow better protection and prevent the cable from rubbing the cable guard tab. Refer to Steps 13, 14, and 15. Pulley Cover BFM Each Cable with a threaded bolt on either end must be threaded at least 1/2 into its attachment, whether it be a Free Floater, Lockout Free Floater, or the Top Plate of the weight stack. Each must also be secured with a 1/2 Jam Nut to ensure a safe and proper connection. Refer to Steps 11, 12, 13, and 24. See Figures below. 1/2 Jam Nut Free Floater w/ Lockout Large Flat Leveler Top Plate Each Adjustment Leveler must be threaded 1/2 into its counterpart. Each must be secured with a 3/8 Jam Nut to ensure a safe proper connection. Refer to Steps 2, 18, and 20. See Figures below. Beveled Leveler 3/8 Jam Nut Batca Fitness Systems 38 Fusion 3 Owner's Manual

39 Preventive Maintenance Batca Fitness Systems strives to give you the very best in quality, performance and safety through carefully engineered designs and excellent workmanship. In order to maintain this high level of quality the preventative maintenance schedule below should be followed. Clean upholstery, grips, and roller pads with mild soap and water generally after every use. The guide rods, chrome slides and frame should be cleaned with a cotton cloth. Upon cleaning the guide rods, a thin layer of Silicone or Teflon gel should be applied to each rod to ensure a glass smooth performance. An overall inspection should be done before each workout. If the warning and safety decals are worn or have been removed they should be replaced immediately. The cables and cable systems should be inspected for signs of wear and proper tension. In order to check cables properly you should carefully run the cable through your fingertips, checking for signs of wear, cracks, burs and thinning spots. Replace any part at first signs of wear. Cables should be adjusted for proper tension. See assembly instructions for this detail. All hardware, stops, and adjustments should be checked and tightened as required. The guide rods on your machine should be cleaned and lubricated regularly. This will ensure a glass smooth performance from your weight stack. A thin layer of either Silicone or Teflon gel should applied to each rod. Each pillow block bearing and flange bearing has a grease fittings that must be lubricated regularly. Use general purpose bearing grease and follow the schedule below. Although cables should be inspected daily, it is important that ALL cables be replaced as directed in the schedule below. Please note that at any first sign of wear the cable should be replaced immediately. If there are any questions concerning maintenance, please contact your local Batca dealer or contact Batca Fitness Systems directly at: Batca Fitness Systems (919) Clean Upholstery Hand Grips Roller Pads Guide Rods Daily Weekly Monthly Quarterly Years Chrome Slides X Frame X Inspect Overall X Safety Decals X Cables X Cable Tension X Pulleys X Hardware X Stops X Upholstery X Hand Grips X Frame X Bushings X Bearings X Lubricate Guide Rods X Bearings 1 Replace Cables Fusion 3 Owner s Manual X X X X

40 What is covered For Residential Use: Limited Lifetime Warranty Batca Fitness Systems warrants all of its products against defects in manufacturing, materials and workmanship under normal use and service for one year from date of purchase including paint, chrome, upholstery and grips. Batca Fitness Systems also warrants all cables, belts, bolts, nuts, caps, plugs, bumpers, washers, levelers, decals, gas springs and other hardware for three years after date of purchase; all moving parts, including pulleys, bushings, bearings and pull pins for five years after date of purchase and warrants the frame and all welded parts for the lifetime of the original purchaser. What is not covered This warranty does not cover damage, which results from shipping, misuse, abuse, neglect, carelessness, modification or alteration, accident, fire, flood, acts of God or other contingencies beyond the control of Batca Fitness Systems. This warranty also does not cover deterioration from wear and tear or exposure or any defect, which would not have happened if instructions in the owner s manual had been followed. Improper installation, improper assembly or follow-up maintenance along with installation of parts or accessories not originally intended for products of Batca Fitness Systems are also not covered by this warranty. Only genuine Batca parts should be used for replacement, repair, and maintenance for this warranty to apply. Defective parts will be repaired or replaced at Batca Fitness Systems option, without parts charge to the purchaser. All returns require a return authorization prior to acceptance of repair work. Batca Fitness Systems reserves the right to make design changes without any prior notification and shall not be responsible for incidental or consequential damages. The purchaser is responsible for shipping the defective part back to the factory. Repair or replacement is the exclusive and sole remedy of the purchaser. Labor charges associated with parts changeovers are not covered by this warranty. Proof of purchase, serial number, model number and date of purchase will be required along with all pertinent information of the alleged damage. This warranty applies only to the original purchaser and is not transferable. Claims under this warranty must be made directly to Batca Fitness Systems. Batca Fitness Systems 1207 N. New Hope Road Raleigh, NC (919) Please keep this for your records. Batca Fitness Systems 40 Fusion 3 Owner's Manual

41 Layout Diagram without Leg Press The Fusion without Leg Press has a layout dimension of 3-11 (width) x /4 (length) x 6-11 (height). There should be a minimum of 18, preferably 24, of working space around the entire unit Fusion 3 Owner s Manual

42 Layout Diagram with Leg Press The Fusion with Leg Press has a layout dimension of 5-5 (width) x /4 (length) x 6-11 (height). There should be a minimum of 18, preferably 24, of working space around the entire unit. Batca Fitness Systems 42 Fusion 3 Owner's Manual

43 Fusion Cable Guide Assembly Instructions The Cable Guide is designed to prevent the Free Floating Pulley Assemblies from twisting. This guide should be installed on both sides of the machine. Please install this part during Step 14. (CAB-13020) From Top Double Pulley Plate Cable Guide (CAB-13020) To Fusion Functional Arms It is important to make sure that the CAB goes through the loop of the Cable Guide properly in the direction shown above for the device to operate correctly. Fusion Cable Guide Assembly